Advanced Plasma Power Plasma Arc Fluidised Bed

ADVANCED PLASMA POWER PLASMA ARC FLUIDISED BED GASIFICATION PLANT Advanced Plasma Power Limited Unit B2, Marston Gate Stirling Road South Marston Business Park Swindon SN3 4DE United Kingdom

Tel: +44 (0)1793 238550 DDI: +44(0)1793 238546 Mobile: +44 7557 377801 [email protected] www.advancedplasmapower.com Plasma Arc Gasification Plants are economical in size compared to Mass Burn Incinerators er. co m

The Gasplasma® Process

Converts RDF feedstock into:

•Converts 97% of the waste fuel •Very clean hydrogen-rich gas •Recyclable aggregate •Minimal emissions / low environmental impact •Negative carbon footprint •Potential CHP Energy efficiencies of >70% •Exporting up to 82% of electricity generated •Local waste, power and heat solution

Briefing Document

General Description Gasplasma® Process

Advanced Plasma Power Process Description

INTRODUCTION

This document describes the process for a Gasplasma® facility that converts circa 150,000 tonnes per annum of Municipal Solid Waste (MSW) and commercial waste into electrical power and heat energy, exporting renewable electrical power to the national or local grid.

This document also describes the core Gasplasma® process equipment and reviews how energy is produced from a waste feedstock.

The Gasplasma® system is designed to be a part of an integrated waste processing system and is at the heart of a dedicated system that includes waste processing, drying, gasification, power and heat generation.

FACILITY OVERVIEW

The whole process can be viewed as three distinct operations (see Figure 1):

 Fuel Preparation The reception of waste and preparation of a Refuse Derived Fuel (RDF)

 Gas Production The conversion of the RDF to a syngas and inert solid aggregate product

 Power Generation Converting syngas to electricity and heat

Fuel Preparation of RDF is based on a maximum design capacity of 150,000tpa of municipal and commercial wastes which, following processing to remove recyclate, moisture and reject materials, produces approximately 90,000 of RDF as feedstock for the Gasplasma® process.

Syngas Production converts the RDF into a synthesis gas (syngas) through the Gasplasma® process which includes cooling, cleaning and conditioning of the syngas. During the syngas cooling stage, steam is produced and is used in the drying process and for power generation.

Power Generation is achieved by converting the syngas into electrical power through reciprocating gas engines. Exhaust gases from the engines produce steam allowing further power generation to take place using a high efficiency steam turbine.

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Advanced Plasma Power Process Description

Waste Reception & Fuel Production RDF

Recyclate Recovery Gasplasma® Syngas Production

Power Generation Glass / Inert matls. Materials Syngas Cooling Non Ferrous Metals Gas Engines & Steam Turbine Dry Syngas Cleaning Ferrous Metals Wet Syngas Cleaning High Density Plastic Exhaust to Atmosphere Syngas Conditioning Moisture

Rejects

Figure 1 - Facility Overview

FUEL PREPARATION

Waste Reception

The waste reception area receives waste deliveries during the agreed operating hours for the facility. All waste is deposited onto a tipping floor for initial visual screening. To allow for fluctuations in delivery volumes the waste reception area is designed to accommodate more than a days’ storage of waste while still leaving manoeuvring space for loading waste into the plant.

The reception area accepts different waste types and incorporates options for pre-sorting and shredding of waste before feeding to the fuel preparation process. Suitable equipment including wheeled front end loaders and a 360 degree “excavator” moves the waste and carries out the stockpiling of materials within the reception area.

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Advanced Plasma Power Process Description

Fuel Preparation

The facility is a single line plant with a nominal design processing rate of up to 25tph allowing up to 150,000tpa of material to be processed. The fuel preparation process operates for up to 24 hrs a day, 6 days per week, depending on the waste deliveries. The first stage of the fuel preparation system is the size classification of material through a rotary screen. The rotary screen then splits the materials into three size categories most suitable for the down stream equipment as follows (see Figure 2):

 Stream 1 Materials less than 15mm  Stream 2 Materials from 15mm to 80mm  Stream 3 Oversize

Stream 1 is mainly dirt, grits, glass, stone and putrescibles. This material stream is transferred directly to containers and is then available for further processing or disposal.

Stream 2 is the correct size range for the Gasplasma® process. Material which can be recycled is removed automatically to leave a feedstock with a high biodegradable content. Materials removed are glass, ferrous metals, non-ferrous metals and dense plastics. Following their removal the remaining materials are conveyed directly to the “wet” fuel store. This store acts as a process buffer store between fuel production and gas production.

Stream 3 is oversize material which, as with Stream 2, is refined by removing recyclable material. The remainder is then passed through a shredder producing a particle size of less than 80mm. It is then combined with Stream 2 in the wet fuel store.

Drying

To improve the consistency of the fuel the material is dried using steam recovered from the Gasplasma® process. The design point of the final dry RDF is 12 -16 MJ/kg, 10-14% moisture and 14-18% ash. Approximately 90,000tpa of RDF is produced from the input tonnage of 150,000tpa. The moisture laden air removed from the RDF is treated to remove odour before release.

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Advanced Plasma Power Process Description

Figure 2 - Fuel Preparation

GAS PRODUCTION

The Gasplasma® system operates on a 24 hour/7 day week basis. At the heart of the facility is an advanced Gasplasma® thermal process that produces a syngas with a calorific value of between 10 and 14MJ/Nm3. The process produces a crude syngas which is treated to remove particulate matter, acid gases and volatile metal vapours. The cool, stable hydrogen-rich syngas which is produced can be used for power generation. Within this section of the facility there are four main process groups (see Figure 4):

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Advanced Plasma Power Process Description

 Gasification  Gas Cooling  Dry Gas Cleaning  Wet Gas Cleaning

Gasification

The Gasplasma® process is made up of two closely coupled but separate operations:

 Gasification of RDF  Plasma Conversion of Gas

Gasification of RDF RDF is fed into the gasifier under strictly controlled conditions. The process environment is maintained by control of oxygen, steam and RDF feed rate. This process provides sufficient heat to maintain the fluid bed temperature and produce a “crude syngas”. The syngas contains significant quantities of long chain hydrocarbons which would condense as tars and residues. The ash component of the RDF is removed from the base of the gasifier through the bed screening process and conveyed to a hopper where it is metered into the plasma converter. There are no residues, chars or ash removed at this stage of the process.

Plasma Conversion of Gas The raw syngas is transferred from the gasifier to the plasma converter via a refractory lined duct. In the centre of the plasma converter is a graphite electrode from which a thermal plasma arc is generated (see Figure 3). The syngas is exposed to elevated temperatures and intense ultra violet light. The effect is to “crack” and reform the tars and chars contained in the syngas into its basic composition of hydrogen (H2), carbon monoxide (CO), carbon dioxide (CO2) and water (H20).

Figure 3 - Image of a Thermal Plasma Arc

The syngas is then drawn via a refractory lined duct to the inlet of the gas cooling system. At all times the gasifier and plasma converter operate at a negative pressure of <-5 to -10 mbar.

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Advanced Plasma Power Process Description

The plasma converter has been designed using computerised flow and modelling techniques to obtain maximum dwell time for the syngas within the converter whilst allowing time for ash and dust particles to drop out of gas stream. These particles are then incorporated into a molten melt which builds up in the base of the converter. The molten material is tapped from the converter and cooled for use as a vitrified and stable material. This material has been approved by the Environment Agency as a product and is trademarked under the name Plasmarok®.

Gas Cooling System

The gas cooling system comprises a heat recovery boiler designed to reduce syngas temperatures from circa 1200ºC to 200ºC and generates steam at 10bar pressure. The basis of the design is a water tube boiler, incorporating robust features as used throughout heavy industry with specific attention given to the materials of construction for long service life and to minimise down time caused by fouling and corrosion. The steam generated is used in the process at the drying and Gasplasma® stage.

Dry Gas Cleaning System

The gas cleaning system, operating at 180-220ºC, removes fine particulate materials from the gas stream, neutralises acidic gas and removes heavy metal vapour.

The syngas passes to the ceramic particulate filter via an insulated duct into which sodium bicarbonate and activated carbon is injected. The duct provides sufficient residence time and turbulence to allow good reaction and collection, providing high capture rates for acidic components. Particulate matter is trapped on the ceramic filter elements and periodically removed using a nitrogen reverse pulse system.

Wet Gas Cleaning System

The syngas enters a quench vessel where the temperature is reduced using water sprays. It then enters a scrubber chamber and flows through two packed beds before being exposed to bio liquor that absorbs the hydrogen sulphide in the syngas.

The bio liquor is passed to a bioreactor where it is aerated and dosed with small quantities of sodium hydroxide to maintain the pH and nutrients for the organisms. Sulphur is filtered out continuously from the circulating solution and recovered. The condensate from the syngas is treated to capture dissolved hydrogen sulphide before being discharged to sewer (meeting the local trade effluent discharge authorisation).

Thermal Oxidiser

A thermal oxidiser is provided to treat all products of combustion, as well as the syngas during the start up phase of the process. This ensures that all emissions to air from the Gasplasma® process meet the requirements of the Waste Incineration Directive. This legislation covers all emissions to air from the treatment of waste in the EU and is regulated in the UK by the Environment Agency via the Environmental Permitting process.

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Advanced Plasma Power Process Description

The thermal oxidiser is configured to remain on hot stand-by at all times the Gasplasma® equipment is operational. This ensures that in the event of an emergency shutdown of the process there is no release of un-combusted gas to atmosphere.

Figure 4 - Gas Production

POWER GENERATION (see Figure 5)

Gas Engines

Dependent upon the manufacture selected, a number of gas engines are installed with the exhaust emissions controlled by efficient combustion control and a system of catalysts and oxidisers. The final engine exhaust emissions also comply with Waste Incineration Directive limits (WID).

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Advanced Plasma Power Process Description

Each engine is provided with an acoustic enclosure that also houses the fire suppressant systems. Exhaust from the engines is routed via a heat exchanger which generates steam for use in a high efficiency steam turbine or for process use.

Off Gas Treatment

During start up, as well as during conditions where the syngas may not meet the required specification for the engines, all syngas is diverted to the thermal oxidiser to allow these gases to be fully oxidised. Emissions from the thermal oxidiser are compliant with the WID regulation. The thermal oxidiser is rated for up to half the design output of the syngas and will be used as a control during normal operation of the Gasplasma® process. At times of normal operating conditions it will be held on hot standby.

Heat Recovery

Heat is recovered from the syngas cooling system and from the gas engine exhausts, which is used in additional power generation or process heating. The normal scheme allows for a high efficiency steam turbine to be used to convert the recovered energy from the gas engine exhaust to electricity. The facility is able to divert steam for use elsewhere in the process (RDF Drying) or for export if there is a suitable third party requirement. Hot water is also available from the engine cooling water systems and is suitable for use in district heating systems and other applications.

Oxygen and Nitrogen Provision

Oxygen and nitrogen supply are provided for use in the Gasplasma® process.

SITE INFRASTRUCTURE

Buildings and Process Areas

The Gasplasma® process can be housed in a building of conventional portal frame design. The building incorporates specific features which make it suitable for processing waste feedstock with significant emphasis placed on odour and noise control.

Waste reception, fuel processing and RDF fuel storage is carried out inside the building which is held under slight negative pressure to prevent odour escape. An exhaust air treatment plant extracts air from the reception area, the fuel preparation equipment and the wet fuel storage area before exhausting via a dry filter and carbon filter system to atmosphere.

The gasifier and plasma converter are also housed within the building whilst the gas cooling, gas cleaning, gas compression and storage systems are all located outside on a suitable concrete pad foundation. The gas engine module is located inside the building with all heat exchangers mounted on the roof of the building.

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Advanced Plasma Power Process Description

The main building includes a reception area at the front entrance of the facility adjacent to a site control office. There is a staircase/lift pod giving access to a high level pedestrian route to the integral offices, control rooms and staff accommodation. Included within this area are educational facilities and viewing access across the process.

Fire Protection

The building and process are protected with sprinkler and/or water cannons systems where required. This includes the waste and RDF storage areas.

Process equipment is protected by a specialist fire control system and all are interlinked to the site wide fire alarm system.

Provision is made for the collection and storage of fire fighting water within the design of the site and buildings.

SYNGAS FLOW

Figure 5 - Power Generation

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Advanced Plasma Power Process Description

Advanced Plasma Power Limited Unit B2, Marston Gate South Marston Business Park Swindon Wiltshire SN3 4DE

Tel; +44 (0)1793 238550

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Fundamentals of Gasplasma® : Principles behind gasification 3500 4.5 Gasification zone 4.0 3000 Towards combustion 3.5 Lambda and CO/CO2 ratio CO/CO2 and Lambda 2500 3.0 C) ° Temperature °C 2000 2.5 CO/CO2 ratio Towards 1500 Lambda 2.0 pyrolysis Temperature( 1.5 1000 1.0 500 0.5

0 0.0 5 15 25 35 45 55 65 75

Oxygen addition (kmols/tonne of RDF) λ= OFR/OFR stoich

Fundamentals: Cracking of organics in plasma converter

The effect of plasma treatment on the reduction of organic species in the syngas

Syngas Composition H2 36% CO 37% CO2 17% N2 3.7% H2O 4.2% CH4 1.4%

Fundamentals: Effect of temperature on tar levels in syngas

3000

2500 Run 118 Run 124

2000

1500

1000 Benzene Concentration (ppm) 500

0 700.00 750.00 800.00 850.00 900.00 950.00 1000.00 1050.00

Converter outlet temperature (oC)

Gasplasma® Outputs: Plasmarok® – A Recycled Aggregate

Summary of results for inert WAC limit compliance BS EN 12457-3 Leaching tests on vitrified sample at particle size <4mm

3.5 Average leachate value (mg/kg) 3 Inert waste landfill Limit values 2.5 (mg/kg) Leachate reading 2 mg/kg 1.5

0.5

0 As Ba Cd Cr Cu Hg Mo Ni Pb Sb Mechanically strong Heavy metal species Se Zn extremely leach resistant Accepted by EA as a Main constituents: Silica 37%; Lime 31% ; Alumina 16% product –not a waste Others include: Iron Oxide; Titania; Magnesia; Sodium Oxide; Potash ; Phosphate

Gas Engine Emissions - compared to EU limits

Emission Gas Engine mg/Nm3 IED (WID) Limits mg/Nm3 CO 31.8 50 NOx 128.9 200 HCl 2.4 10 SO2 15.8 50 Particulate 5.6 10 VOC/TOC <1 10 Dioxins / Furans Undetectable < 0.1 ng / Nm3 ITEQ

Main Exhaust Gases (by weight) CO2 13%; H2O 5%; O2 13% ; N2 69%

© 2010 Advanced Plasma Power Ltd Unit B2, Marston Gate, Stirling Road, South Marston Business Park, Swindon, Wiltshire SN3 4DE. T: 01793 238550 www.advancedplasmapower.com THE Energy From Waste Solution

Plasmarok® - recovered from the Advanced Plasma ® Power Gasplasma energy UK Environment from waste process Agency Approved: What is Plasmarok®: Certainty of use: Plasmarok® Plasmarok® is the fully vitrified, mechanically strong and has demonstrated that there is a environmentally stable and inert product that is recovered need and a market for the from the Advanced Plasma Power Gasplasma® energy from waste process. Simply put, it’s a material that has been recovered waste reduced to a stable and inert product by being subjected to Suitability for use: Plasmarok® extreme heat. has been independently tested and passed BS EN 13242:2002 How is Plasmarok® made: standards as an unbound Plasmarok® is formed in the heart of the plasma converter aggregate in civil engineering where the intense heat (around 8,000oC) reduces the ash construction projects. For example, forming part of the waste feedstock into a molten vitreous in pipe bedding applications and material resembling volcanic lava. road construction aggregate No risk to the environment or The particular technique employed for treating the molten human health: Plasmarok® has stream exiting the plasma converter can be adjusted to undergone independent leachate suit the end-use application for the product. For example, testing against BS EN 12457 and the molten material can be rapidly cooled and granulated has demonstrated that there is no in a water bath to form a <10mm product that would be appropriate for use as a pipe bedding material. potential to cause pollution or harm to human health when it is stored Alternatively, casting the material into blocks and allowing or used it to cool more slowly produces a high strength product that may be used as a sub-base material for a high load bearing structure.

Why Plasmarok® is safer than alternatives: APP’s Gasplasma® technology Plasmarok® is more suited to a wider range of uses than economically converts waste fuels residues generated in other thermal conversion processes, into two recyclable products; such as conventional incineration. Incineration bottom i. A clean, hydrogen rich synthesis ash contains leachable levels of heavy metals becoming gas (syngas), capable of generating potentially toxic, and the fly-ash contains heavy metals high electrical output and other hazardous constituents and is therefore classed as hazardous waste under the European waste catalogue. ii. An inert product (Plasmarok®) Other technologies typically produce solid residues that that can be reused as a contain high levels of chars, tars and heavy metals that building material may also require disposal to hazardous landfill.

Telephone: +44 (0)1793 238 550 www.advancedplasmapower.com THE Energy From Waste Solution

Plasmarok® has gone through comprehensive testing Advanced Plasma Power has successfully to ensure its safety against British Standard EN developed and operates a comprehensive 1342:2002 standards. Gasplasma® facility in Swindon. As a group we are experts in the use of Plasma; a clean, Uses for Plasmarok®: controllable, omnivorous technology that the group has been supplying since 1964 with Plasmarok®’s unique combination of high mechanical 80 installations. strength and hardness, as well as extremely high resistance to chemical leaching make it perfect for use as a secondary APP’s Gasplasma® technology economically aggregate material (material that has been used, then converts waste fuels into two products: recycled and recovered) in road paving, pipe bedding or other markets. In addition, tests have proven that i. A clean, hydrogen rich synthesis gas Plasmarok® is less vulnerable to the cracks and weakness (syngas), capable of generating high heat that may reduce other materials resistance to fracture. and power output

ii. An inert product (Plasmarok®) that can be UK Environment Agency Approved: reused as a building material The UK Environment Agency states that Plasmarok® meets the criteria set out in the Waste Framework Directive The technology is patented nationally (“WFD”) (Directive 2008/98/EC), which acknowledges and internationally. Plasmarok® as a product and not a waste.

To achieve this status Plasmarok® has met the following requirements: About Advanced Plasma Power Advanced Plasma Power (APP) Certainty of use: Plasmarok® has demonstrated that Limited is the world’s first there is a need and a market for the recovered waste waste-to-energy company ® Suitability for use: Plasmarok has been using breakthrough Gasplasma® independently tested and passed BS EN 13242:2002 technology able to treat a wide standards as an unbound aggregate in civil range of feedstocks. Gasplasma® engineering construction projects. For example, is based on proven sub-systems in pipe bedding applications and road that offer an effective solution construction aggregate to two of the world’s most No risk to the environment or human health: significant environmental issues: Plasmarok® has undergone independent leachate the need for low carbon renewable testing against BS EN 12457 and has demonstrated energy and the need for cleaner, that there is no potential to cause pollution or harm to environmentally sustainable, waste human health when it is stored or used management solutions.

Advanced Plasma Power Limited - B3 Marston Gate - South Marston Business Park - Swindon, SN3 4DE

Telephone: +44 (0)1793 238 550 www.advancedplasmapower.com

Registered in England Number 5633910 - VAT number 872 9093 88 - Registered address: 7th Floor, 52/54 Gracechurch Street, London, EC3V 0EH, UK